Collecting and bundling device for use with fiber-drafting machine

ABSTRACT

This invention relates to an apparatus for a fiber drafting machine which collects and bundles drafted fibers together using airflow. A double structured pipe N is installed on the fiber drafting machine to allow the fibers to be gathered together using airflow. The drafting machine is equipped with 2 zones, Z 1  and Z 2 . Z 1  has a pair of front rollers R 1  and a pair of delivery rollers R 4  located on the downstream of R 1 , and a double pipe structured collecting nozzle N is located between the rollers R 1  and R 4 . This collecting nozzle N consists of an inner nozzle N 1 , which contains the inner space, or fiber path  5  for the fibers to go through, and an outer nozzle N 2 , which is located outside of the inner nozzle N 1 . There is a loop-like space in the area between N 1  and N 2 . This loop space will be used as an airflow path  1,  and its design will allow for low pressure airflow to enter from the outside. Nozzle entrance  2  is located on the upstream side of inner nozzle N 1 . When you close the upstream of air flow path  1,  the downstream side opening of air flow path  1  will have its cross sectional area rapidly reduced. When this occurs the airflow path  1  will merge with the fiber path  5.

FIELD OF THE INVENTION

[0001] This invention relates to a fiber collecting and bundling device which attaches to a fiber drafting machine which will allow the drafted fibers to be collected inside the collecting nozzle using low pressure airflow induced from the outside.

BACKGROUND OF THE INVENTION

[0002] The fiber drafting machine, as shown in FIG. 1 of this invention, has a structure that consists of multiple pairs of draft rollers, R₁, R₂, and R₃ positioned at definite intervals. The uppermost downstream pair of draft rollers are referred to as the front rollers R₁. The area between the front rollers R₁ and the draft rollers R₂ is designated as the main draft zone Z₁. The draft rollers R₂ are located in the immediate upstream of the front rollers R₁. The upstream area between the draft rollers R₂ and the draft rollers R₃ is designated as the break draft zone (pre-draft zone) Z₂.

[0003] The bundle of fibers located in the main draft zone Z₁, because of their volume, are more likely to spread. These spread fibers, when they arrive at the exit area of the main draft zone Z₁, will be nipped by a pair of front rollers R₁. When the fibers are nipped at the exit area they will be spread and forwarded to the twisting process. These fibers that are forwarded to the twisting process are spread sideways (in the direction of the width). FIG. 5a reveals this twisting process occurring. When the spread fibers are twisted, end parts on both sides (in the direction of the width) of the spread fibers will not be twisted in together as a body of yarn, instead, only one end of these sides will be twisted inward. The fibers that are twisted by only one end can not adequately contribute to the strength of the yarn, in addition, later in the process the fiber in this condition will stay fluffed leading to further problems. P′ in FIGS. 5a-5 c show the nip point of the front rollers R₁.

[0004] A common method to reduce the deficiencies inherent in the spinning process is, as shown in FIG. 5b, to install a pair of collectors 51 slightly upstream from the aforementioned nip point P′, so that they would prevent the collected fibers from spreading. However, there is a problem with using this common method which allowed the high speed running fibers to touch these collectors 51 directly. This direct touch would result in friction which would damage the quality of the fibers. The direct touch process itself does nothing to make the collection process more efficient.

[0005] Because of the above referenced reasons, various kinds of collecting and bundling devices have been suggested. For example, a collecting and bundling device can be installed in the condense zone Z₃. The condense zone Z₃ is located between a pair of front rollers R₁ and a pair of delivery rollers R₄. The delivery rollers R₄ are located in the downstream of the front rollers R₁. Using this type of device, the fibers can be collected by a collecting and bundling device after they are drafted inside the main draft zone Z₁.

[0006]FIG. 8 shows a fiber collection structure where a front roller R₁ and a delivery roller R₄ both are in contact with a roller 52 which has many perforations. This perforated roller 52 is located in zone Z₃, making contact with R₁ and R₄, to allow the fibers F be collected with the help of suctioning airflow, as the fibers are passing through zone Z₃ by passing along the outer circle of the perforated roller 52. Also, FIG. 9 reveals a structure for the fibers F to be gathered with the aid of suctioning airflow while the fibers F are passing along the bottom of a solid screen section, 53 in zone Z₃. FIG. 10 shows a structure for the fibers F to be gathered with the aid of suctioning airflow using a perforated apron 54. While the drafted fibers F are passing along the edge of the perforated apron 54 located in the condense zone Z₃, the apron 54 is in contact with the delivery roller R₄ which is turning. Simultaneously, the suctioning airflow will enter thus allowing the fibers F to be collected.

[0007] All of the above mentioned collecting and bundling devices used the same type methods. These methods allowed for the drafted fibers to be gathered together using suctioning airflow. The suctioning airflow worked in conjunction with the device in the area where the fibers came into contact with the device. While these drafted fibers were being gathered, they naturally would come into contact with parts of the device. Because contacts between the device and the fibers were inevitable using the prior methods, there were inherent deficiencies caused by heat and friction that lead to the severance of the fibers. These methods offer an improvement when compared to the collection method 51, but the methods are still insufficient.

SUMMARY OF THE INVENTION

[0008] This invention collects fibers through the use of airflow without any contact between the drafted fibers and a collecting device attached to a fiber drafting machine.

BRIEF DESCRIPTION OF THE FIGURES OF DRAWINGS

[0009]FIG. 1 is a side view of the bundled fiber drafting machine equipped with the collecting and bundling device attached.

[0010]FIG. 2 is a top view of the collecting nozzle unit U.

[0011]FIG. 3 is a vertical cross sectional view of the collecting nozzle N.

[0012]FIG. 4 is a magnified side view showing the location and relationship between a pair of delivery rollers R₄ and the collecting nozzle N.

[0013]FIG. 5a illustrates the fibers being gathered when the collecting and bundling device is not used.

[0014]FIG. 5b illustrates the fibers being gathered with the use of a pair of collectors 51.

[0015]FIG. 5c illustrates the fibers being gathered with the aid of inducing airflow.

[0016]FIG. 6 is a vertical cross sectional view of a second collecting nozzle N′ in this invention.

[0017]FIG. 7a is the right side view of inner nozzle N′

[0018]FIG. 7b is the right side view of outer nozzle N₂′

[0019] Both nozzles together form the above mentioned collecting nozzle N′.

[0020]FIG. 8 is a side view of the prior conventional drafting machine with perforated rollers 52 located in condense zone Z₃.

[0021]FIG. 9 is a side view of a prior conventional drafting machine with a screen 53 located in condense zone Z₃.

[0022]FIG. 10 is a side view of a prior conventional drafting machine with perforated apron 54 located in condense zone Z₃.

[0023] Explanation of symbols used in the figures of drawing:

[0024] A₁: Blown-in airflow

[0025] A₂: Induced airflow

[0026] F: Fibers

[0027] N, N′: Collecting nozzle

[0028] N₁, N₁′: Inner nozzle

[0029] N₂, N₂′: Outer nozzle

[0030] R₁: Front roller (draft roller)

[0031] R₄: Delivery roller

[0032] R₅: Carrier roller

[0033] U: Collecting nozzle unit

[0034] Z₁: Main draft zone

[0035] Z₂: Break draft zone

[0036] Z₃: Condense zone

[0037]1: Airflow path

[0038]2: Nozzle entrance

[0039]3: Nozzle body

[0040]3 a: A rectifying groove

[0041]4: Discharge cylinder

[0042]4 a, 4 b: A rectifying groove for discharge cylinder

[0043]5: Fiberpath

[0044]6: Nozzle exit

[0045]7: Joint area

[0046]9: Exit of outer nozzle, tapered

[0047]9 a: A rectifying groove for the outer nozzle

[0048]12: Side frame (collecting nozzle unit)

[0049]13: Supporting rod (collecting nozzle unit)

[0050]14: Supporting arm (collecting nozzle unit)

DETAILED DESCRIPTION OF THE INVENTION

[0051] This invention solves the above referenced problems. The invention is a fiber drafting machine with special new characteristics. This fiber drafting machine has a mechanism that consists of two zones, a main draft zone and a break draft zone. The fiber drafting machine has a collecting and bundling device installed. The collecting and bundling device has a double nozzle installed between a pair of front rollers in the main draft zone and a pair of delivery rollers in the downstream. This nozzle is equipped with an inner nozzle, which works as a path for the fibers, and with an outer nozzle, which is installed outside of the inner nozzle. There is a loop area created in the space between the two nozzles which allows for low pressure air to enter from the outside. The upstream of the above mentioned air path is closed. The upstream of the inner nozzle provides an entrance for the fibers to enter the device. The downstream opening of the air path has its cross-sectional area being rapidly reduced as it is merged with the fiber flow path.

[0052] According to this invention, when low pressure air is blown into the air path in the loop space area created between the inner and the outer nozzle, the air will flow through the rapidly narrowed cross sectional area, continue to flow to the joint area of the air and the fibers, and then continue its flow to the exit of the nozzle. Therefore, the blown-in low pressure air in the path at the joint area will suddenly increase in speed and create a negative pressure. At the fiber path, outside air is induced and taken in from the entrance of the nozzle to create an induced airflow. This induced airflow has the ability to wrap the fibers from the outside in a three dimensional way, which will further enable the collection of the fibers without any contact with the surface area inside the nozzle.

[0053] This invention has another special characteristic in addition to the above characteristics. A special characteristic of this invention is the rectifying grooves that are located on both the inner and outer nozzle. These rectifying grooves are located on the surface area of each nozzle and are placed in the direction of the airflow. In this invention low pressure air is induced from outside into the space between the inner and the outer nozzle. Further, there is another airflow occurring which moves the fibers inside the inner nozzle. These two airflows flow along the rectifying grooves to both control and prevent the air from turning around. As a result, of these airflows there is an increase in the fiber collecting ability because when the air becomes rectified, it will assist the fibers to be collected and will prevent the fibers from spreading.

[0054] This invention has another special characteristic in that the cross sectional area at the exit of the fiber collecting nozzle will rapidly narrow and reduce. Because of this rapidly narrowing characteristic the airflow speed in the fiber path inside the inner nozzle is faster at the exit opening and the airflow pressure will be lowered at the exit. This effect will increase the negative pressure of the airflow at the joint area mentioned above and this increased negative pressure will be more likely to induce airflow.

[0055] This invention also has a special characteristic in that the collecting nozzle is installed in a way that its exit is located close to the nip point of a pair of delivery rollers. Normally, the fibers and the air collected inside the nozzle are discharged from the nozzle and will be likely to spread as they exit. However, when using this design and by locating and installing a pair of delivery rollers close to the nip point, this design will prevent the fibers spreading effect and lead the fibers directly into contact with the delivery rollers.

[0056] This invention also has a special characteristic in that the collecting nozzle and a pair of delivery rollers are assembled together to be a collecting nozzle unit. The advantage of having a unit like this is that by having one unit it is easier to install without adjusting the distance between the unit and the device and without further having to adjust the angle between the path for the fibers coming through the draft section (thread path) and the path for the fibers to travel downstream of the draft section.

[0057] Additionally, by installing and adding a carrier roller, which conveys the revolutions from front rollers, to this collecting nozzle unit, not only will the peripheral velocity of delivery rollers and front rollers be uniform, but in addition the delivery rollers' driving mechanism can be operated without the fibers being drafted needlessly inside the collecting nozzle.

[0058] As shown in FIG. 1 and FIG. 2, a pair of delivery rollers R₄ is located in the downstream of a pair of front rollers (draft rollers) R₁, the collecting nozzle N is installed between the rollers R₁ and R₄, and a condense zone Z₃ is located between both sets of rollers R₁ and R₄. To enable the direct proximity of the location of nozzle exit 6 to the collecting nozzle N and to further maintain the desired closeness of the collecting nozzle N to the nip point P of a pair of delivery rollers R₄, the external diameter of the delivery rollers R₄ must be significantly less than the external diameter of each draft roller R₁ to R₃. The path for the fibers F (thread path) in the condense zone Z₃ is shown crossing the path of the fibers F (thread path) in the draft area with the angle of θ (in this example, approximately 20 degrees). The draft rollers, R₁ to R₃, are made of steel and the delivery rollers R₄ are made of rubber. In FIG. 1, number 21 depicts an apron covering a pair of draft rollers R₂, and the fibers F pass between a pair of aprons 21 in the main draft zone Z₁.

[0059] As shown in FIG. 3, the collecting nozzle N consists of a cylindrical inner nozzle N₁ and an externally attached external nozzle designated N₂ The end portion of external nozzle N₂ has a conical cylinder shape. The loop area created between the nozzles N₁ and N₂ is an airflow path 1 for low pressure air to be induced into the nozzles from outside the nozzles. The airflow path 1 is closed in the upstream and the opening on the upstream side of nozzle N₁ is designated as nozzle entrance 2. At the edge of inner nozzle N₁′s main body 3 is a discharge cylinder 4. The discharge cylinder 4 is installed and its inner diameter is smaller than the nozzle body 3's diameter. The edge of the discharge cylinder 4 is cylindrical and it is protruding toward the conical shape of the nozzle end of the outer nozzle N₂. Therefore, the cross sectional area of the fiber flow path 5 inside of inner nozzle N₁ is larger at the nozzle entrance 2 in the up stream and it becomes smaller just before the joining area where the fibers meet with the airflow path 1 in the downstream.

[0060] The cross sectional area of the downstream side of airflow path 1, being loop-like, rapidly becomes smaller and meets with the fiber flow path 5, and the down stream side opening is exit 6 of the outer nozzle N₂. This means that the joining area 7 of the airflow path 1 and the fiber flow path 5 is slightly upstream of nozzle exit 6. The uppermost upstream area of the airflow path 1 inside external nozzle N₂ is an induction hole 8 installed in the direction of the radius to allow low pressure airflow in.

[0061] As shown in FIGS. 1 and 2, the nozzle N and a pair of delivery rollers R₄ are assembled together as a unit. This unit then forms a collecting nozzle unit U by installing a carrier roller R₅ to convey the revolutions of the front rollers R₁ to the delivery rollers R₄. The turning axis of the delivery rollers R₄ is supported by the side frames 12 on both sides. The collecting nozzle N is located between frames 12 and is supported by supporting rods 13 on both sides. A pair of side frames 12 is supported by another frame which is part of the draft device (not depicted in the diagram). Located outside of the side frames 12 are supporting arms 14. The supporting arms 14 are located on the outside of the side frames 12 on both sides. The base part of the supporting arms 14 are supported by the turning axis 11 of the bottom delivery roller R₄. Located between a pair of supporting arms 14, is a carrier roller R₅. The turning axis of carrier roller R₅ is supported by the other side of the supporting arm 14. This carrier roller R₅ is a magnetic roller and the surface is covered with a rubber cot.

[0062] Using this method to install a collecting nozzle N, etc. onto the drafting device is simpler than prior art installations. This is due to the fact that collecting nozzle N, a pair of delivery rollers R₄, and carrier rollers R₅ are assembled together as a collecting nozzle unit U. Simply place the nozzle unit U in the designated location on the downstream side of front rollers R₁ and fix it onto the nearby frame at a certain crossing angle θ of the collecting nozzle N instead of placing each nozzle N, roller R₄, and roller R₅ separately in the required correct positions to work. The angle θ of the path for fibers F in the draft area (thread path) to cross with the path for the fibers F at the immediate downstream of the draft area needs to be adjusted depending on the angle of the fibers spun out of the draft area. Using nozzle unit U, this adjustment can be accomplished easily. Consequently, the installation of the collecting nozzle N on any draft device will become simpler whether using the new drafting machine or an existing drafting machine.

[0063] When carrier roller R₅ is drawn to the front bottom roller R₁ by the use of magnetic power, the turning force of the front bottom roller R₁ will then be conveyed to the bottom delivery roller R₄ via carrier roller R₅, which turns a pair of delivery rollers R₄ in the reverse direction. Because the pair of delivery rollers R₄ are made of rubber and the surface of carrier rollers R₅ are covered with rubber cot, the revolution of the front bottom rollers R₁ are conveyed to a pair of delivery rollers R₄ without slippage. Additionally, the peripheral velocity of the delivery rollers R₄ will be the same as the peripheral velocity of the front rollers R₁. This will enable the fibers to pass through the collecting nozzle N located between R₁ and R₄ smoothly without being drafted.

[0064] Also, as shown in FIG. 1 and FIG. 4, the external diameter of the delivery rollers R₄ is far smaller than that of the external diameters of the other draft rollers R₁ to R₃. This is necessary in this design so that the nozzle exit 6 at the end of collecting nozzle N (end of downstream) can be placed next to the nip point P of delivery rollers R₄.

[0065] A condition exists that allows low pressure airflow to continue blowing from the induction hole 8 of the outer nozzle N₂ towards the air path 1. A loop space is created between the inner nozzle N₁ and the outer nozzle N₂. Fibers F flow toward the collecting nozzle N after being drafted inside the draft zones Z₂ and Z₁ in the upstream location, then the airflow A₁ flowing in the air path 1 flows through joint area 7. The sectional area of joint area 7 is the area where it is rapidly reduced and merged with the fiber path towards the nozzle exit 6. Due to this design, the speed of the low pressure blown-in air A₁ flowing in the air path 1 becomes rapidly faster at the joint area 7 where it meets with the fiber path 5, which creates negative pressure in joint area 7. This leads outside air to be taken in from nozzle 2 to fiber path 5 and create induced airflow A₂. Because of the fact that the induced airflow A₂ will flow and wrap the fibers F from the outside in a three dimensional way, the fibers F flowing inside the fiber path 5 will be collected inside the fiber path 5 without touching the inner surface area of the fiber path 5 (see FIG. 5c) and exits from nozzle exit 6.

[0066] Fiber path 5 of the inner nozzle N₁ inside the collecting nozzle N in this example has its cross section being reduced in the downstream, which will then increase the negative pressure even more in the joining area 7. This will make the non-contact fiber collecting job inside the collecting nozzle N even more effective. The fibers F will be collected inside the collecting nozzle N without contacting or touching the surface area of the collecting nozzle N. At that point the airflow within the collected fibers F will try to spread at the nozzle exit 6 again, however, this nozzle exit 6 is closely located to the nip point P of a pair of delivery rollers R₄ which will prevent the spreading of the fibers F, and the fibers F will be immediately nipped by the delivery rollers R₄.

[0067]FIG. 6 shows a different example of the vertical cross section of the collecting nozzle N′. FIGS. 7(a) and (b) reveals the inner components of the collecting nozzle N′, showing the right side view of inner nozzle N₁ and of the outer nozzle N₂ separately. The collecting nozzle N′ is equipped with a large number of rectifying grooves, 3 a, 4 a, and 4 b, and they are located towards the direction of the airflow on the surface of the inner circumference of the inner nozzle N₁′, which is a component of the collecting nozzle N′. On the surface of the inner circumferences of the of nozzle's main body 3, there are a series of rectifying grooves 3 a which are uniformly distributed in the direction of the inner circumference of the nozzle. The discharge cylinder 4, with its internal diameter being smaller than the diameter of the nozzle's main body 3, also has a large number of rectifying grooves 4 a located on the surface of its inner circumference. Both 3 a and 4 a are connected to each other via a rectifying groove 4 b located on the surface of the inner circumference of the tapered entrance on the discharge cylinder 4. A large number of rectifying grooves 9 a are also installed on the inner circumference surface of the tapered exit 9 on the outer nozzle N₂′. These rectifying grooves 9 a are located in the direction of the low pressure airflow induced from outside.

[0068] Because of the fact that the airflow inside the fiber path 5 of inner nozzle N₁′ is flowing along in the direction of the rectifying grooves of 3 a, 4 b, and 4 a of the internal circumference surface, and because of the additional fact that this low pressure air inside the air path 1 between inner nozzle N₁′ and outer nozzle N₂′ is flowing along the rectifying groove 9 a on the internal circumference surface of the tapered exit part 9 of the outer nozzle N₂′, the occurrence of a turning flow can be controlled and/or prevented. As a result, the above mentioned airflows will become rectified, and the fibers will not be spread by a turning airflow. This rectification of the airflow will make the collecting capability more effective.

[0069] In the above referenced example, the cross sectional area of the fiber path 5 of the inner nozzle N₁, which is a part of the collecting nozzle N, is smaller at the discharge than the one at the entrance. Due to this design, the fiber collecting task can be achieved. However, the cross sectional area of the fiber path 5 can be the same in all areas. This invention makes it possible to spin out a stronger, less fuzzy and evenly spun thread by solving any aforementioned spinning deficiencies. This invention has a double piped structure built into the collecting nozzle between a pair of front rollers in the main draft zone and a pair of delivery rollers in the downstream of the front rollers. When the fibers are spun out, a negative air pressure is created in the joining area of the airflow path, through which the outside air is induced into the collecting nozzle, and fiber flow path. The air from outside will be induced from the nozzle entrance to produce induction airflow. This induced airflow will then wrap the drafted fibers from the fiber's outer circumference in a three dimensional way inside the collecting nozzle. By using this method, the fibers are collected without any contact with the inner circumference surface area of the nozzle and thus they are stronger, less fuzzy, and spun evenly.

[0070] The invention as disclosed herein is subject to various modifications and variations will be seen by those of ordinary skill in the art. The invention is therefore not limited solely to the apparatus specifically described, but is intended to have the scope as set forth in the following claims. 

What is claimed is:
 1. A collecting and bundling device which can be installed onto a textile drafting machine, comprising: a main draft zone, a break draft zone, a double pipe collecting nozzle between a pair of front rollers in the main draft zone, a pair of delivery rollers at the downstream, said collecting nozzle having both an inner nozzle and an outer nozzle, the inner nozzle having an inner space to allow the fibers to pass therethrough, a loop-like space between the inner and the outer nozzle, said loop-like space forming a path for low pressure airflow which enters from the outside, whereby the upstream airflow path is closed, therefore, and the inner nozzle's opening on the upstream side provides an entrance for the fibers, while the opening of the airflow path has its cross sectional area rapidly reduced in size to allow the fibers to merge.
 2. The fiber collecting and bundling device according to claim 1 wherein both the inner and outer nozzles have grooves located along the airflow path on the surface of the inner circumference.
 3. The fiber collecting and bundling device of claim 1 wherein the nozzle has a fiber path opening for the fibers to exit, with its cross sectional area being rapidly reduced.
 4. The fiber collecting and bundling device of claim 1 wherein the collecting nozzle is located close to the nip point of a pair of delivery rollers.
 5. The fiber collecting and bundling device of claim 1 wherein the collecting nozzle and a pair of delivery rollers together form a collecting nozzle unit.
 6. The fiber collecting and bundling device of claim 5 having a collecting nozzle unit with a carrier roller which conveys the revolutions from front rollers to the delivery rollers. 